MQ Multiquip SGW-250SS User manual

MQ POWER

PARTS AND OPERATION MANUAL

WHISPERWELD

TM

DC WELDER/AC GENERATOR

Model SGW-250SS

Revision #2 (08/08/01)

MULTIQUIP INC. PARTS DEPARTMENT:

18910 WILMINGTON AVE. 800-427-1244

CARSON, CALIFORNIA 90746 FAX: 800-672-7877

310-537-3700

SERVICE DEPARTMENT:

800-421-1244 800-478-1244

FAX: 310-537-3927 FAX: 310-537-4259

E-mail:[email protected] • www:multiquip.com

Parts No. D2845200004A

PAGE 2 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)

SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — PAGE 3

HERE'S HOW TO GET HELP

PLEASE HAVE THE MODEL AND SERIAL NUMBER

ON-HAND WHEN CALLING

PP

P

ARAR

AR

TS DEPTS DEP

TS DEP

ARAR

AR

TMENTTMENT

TMENT

800/427-1244 or 310/537-3700

FAX: 800/672-7877 or 310/637-3284

SERSER

SER

VICE DEPVICE DEP

VICE DEP

ARAR

AR

TMENTTMENT

TMENT

800/835-2551 or 310/537-3700

FAX: 310/638-8046

WW

W

ARRANTY DEPARRANTY DEP

ARRANTY DEP

ARAR

AR

TMENTTMENT

TMENT

800/835-2551 or 310/537-3700

FAX: 310/638-8046

MAINMAIN

MAIN

800/421-1244 or 310/537-3700

FAX: 310/537-3927

PAGE 4 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)

TABLE OF CONTENTS

Here's How To Get Help ............................................ 3

Table Of Contents ..................................................... 4

Parts Ordering Procedures ....................................... 5

Rules For Safe Operation ...................................... 6-7

Operation and Safety Decals ................................. 8-9

Specifications .......................................................... 10

General Information ................................................ 11

Dimensions ............................................................. 12

Trailer Safety Guidelines .................................... 13-17

Trailer Wiring Diagram............................................. 18

Towing ..................................................................... 19

Controls and Indicators ...................................... 20-21

Installation ............................................................... 22

Pre-Setup ........................................................... 23-25

Instrumentation ....................................................... 26

Load Application ..................................................... 27

Welder Operating Instructions ........................... 28-30

Engine Operating Instructions ................................ 31

Maintenance ...................................................... 32-33

Preparation For Long Term Storage ....................... 34

Engine/Generator Wiring Diagram .......................... 35

Troubleshooting (Welder) ....................................... 36

Troubleshooting (Engine) ................................... 37-39

Explanation Of Codes In Remarks Column ............ 40

Suggested Spare Parts ........................................... 41

MQ Power SGW-250SS—

DC Welder/AC Generator

Generator Assembly .......................................... 42-43

Control Panel Assembly ..................................... 44-47

Electric Parts Assembly...................................... 48-49

Battery Assembly ............................................... 50-51

Tail Pipe Assembly ............................................. 52-53

Fuel Tank Assembly ........................................... 54-55

Enclosure Assembly ........................................... 56-57

Name Plate And Decals ..................................... 58-59

NOTE

Specification and part numberSpecification and part number

Specification and part number

are subject to change withoutare subject to change without

are subject to change without

noticenotice

notice

..

.

Honda GX610VXD Engine

Cylinder Head Assembly ....................................60-61

Cylinder Barrel Assembly ...................................62-63

Crankcase Cover Assembly ...............................64-65

Crankshaft Assembly ......................................... 66-67

Piston Assembly .................................................68-69

Camshaft Assembly ...........................................70-71

Fan Cover Assembly ..........................................72-73

Carburetor Assembly .........................................74-75

Air Cleaner Assembly.........................................76-77

Muffler Assembly ...............................................78-79

Fuel Pump Assembly ......................................... 80-81

Flywheel Assembly ............................................82-83

Ignition Coil Assembly ........................................ 84-85

Starter Motor Assembly .....................................86-87

Control Assembly ...............................................88-89

Terms and Conditions Of Sale — Parts .................. 90

SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — PAGE 5

PARTS ORDERING PROCEDURES

Get special freight allowances

when you order 10 or more

line items via FAX!**

■

UPS Ground Service at no charge for freight

■

PS Third Day Service at one-half of actual freight cost

No other allowances on freight shipped by any other carrier.

**Common nuts, bolts and washers (all items under $1.00 list price)

do not count towards the 10+ line items.

*DISCOUNTS ARE SUBJECT TO CHANGE*

Fax order discount and UPS special programs revised June 1, 1995

Earn Extra Discounts when

you order by FAX!

All parts orders which include complete part numbers

and are received by fax qualify for the following extra

discounts:

Number of

line items ordered Additional Discount

1-9 items 3%

10+ items** 5%

Now! Direct TOLL-FREE access

to our Parts Department!

Toll-free nationwide:

800-421-1244

Toll-free FAX:

800/6-PARTS-7 • 800-672-7877

■ Dealer account number

■ Dealer name and address

■ Shipping address (if different than billing address)

■ Return fax number

■ Applicable model number

■ Quantity, part number and description of each part

■ Specify preferred method of shipment:

•

UPS Ground

•

UPS Second Day or Third Day*

•

UPS Next Day*

•

Federal Express Priority One (please provide us with your Federal

Express account number)*

•

Airborne Express*

•

Truck or parcel post

*Normally shipped the same day the order is received, if prior to 2PM west coast time.

Extra Fax Discount

for Domestic USA

Dealers Only

PAGE 6 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)

RULES FOR SAFE OPERATION

CAUTION:

Failure to follow instructions in this manual may

lead to serious injury or even death! This

equipment is to be operated by trained and

qualified personnel only! This equipment is for

industrial use only.

The following safety guidelines should always be used when

operating the SGW-250SS Welder/AC Generator :

GENERAL SAFETY

■

DO NOT operate or service this equipment before

reading this entire manual.

■

This equipment should not be operated by

persons under 18 years of age.

■

NEVER operate this equipment without proper

protective clothing, shatterproof glasses, steel-

toed boots and other protective devices required

by the job.

■

NEVER operate this equipment when not feeling

well due to fatigue, illness or taking medicine.

■

NEVER operate this equipment under the

influence or drugs or alcohol.

■

NEVER use accessories or attachments, which are not

recommended by MQ Power for this equipment. Damage to

the equipment and/or injury to user may result.

■

Manufacture does not assume responsibility for any accident

due to equipment modifications.

■

Whenever necessary, replace nameplate, operation and

safety decals when they become difficult read.

■

Always check the machine for loosened threads or bolts

before starting.

■

Always refuel in a well-ventilated area, away from sparks and

open flames.

■

Always use extreme caution when

working with flammable liquids. When

refueling, stop the engine and allow it

to cool. DO NOT

smoke around or near

the machine. Fire or explosion could

result from fuel vapors, or if fuel is

spilled on a hot engine.

■

NEVER operate the generator in an explosive atmosphere

or near combustible materials. An explosion or fire could

result causing severe

bodily harm or even death.

■

Topping-off to filler port is dangerous, as it tends to spill

fuel.

■

NEVER touch the hot exhaust

manifold, muffler or cylinder. Allow

these parts to cool before servicing

engine or generator.

■

The engine of this welder/generator requires an adequate

free flow of cooling air. Never operate the generator in any

enclosed or narrow area

where free flow of the air is

restricted. If the air flow is

restricted it will cause serious

damage to the welder/

generator engine and may

cause injury to people.

Remember the welder/

generator's engine gives off

DEADLY carbon monoxide

gas.

■

High Temperatures – Allow the engine to cool before

adding fuel or performing service and maintenance

functions. Contact with

hot

components can cause serious

burns.

SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — PAGE 7

CAUTION:

This generator is a source of providing

LETHAL high voltages. Never permit

unqualified personnel-especially children to

operate the generator.

■

Always refuel in a well-ventilated

area, away from sparks and open flames.

■

This generator is equipped with a

ground terminal ground terminal

ground terminal

for your

protection. Always complete the grounding path from the

generator to an external grounding source.

■

NEVER operate this generator, or handle any electrical

equipment while standing in

ww

w

aterater

ater

, while bare f, while bare f

, while bare f

oot, whileoot, while

oot, while

hands are wet, or in the rain. hands are wet, or in the rain.

hands are wet, or in the rain. Dangerous electrical shock

could occur causing severe bodily harm or even death.

■

Keep electrical cords in good condition. Worn, bare or frayed

wiring can cause electrical shock, thus causing

bodily harm

or even death.

■

This generator requires an adequate free flow of cooling

air. Never operate the generator in any enclosed or narrow

area where free flow of the air is restricted. If the air flow is

restricted it will cause serious damage to the generator and

may cause injury to people.

■

NEVER touch the hot exhaust manifold, muffler or cylinder.

Allow these parts to cool before servicing generator.

■

Provide adequate ventilation when operating the generator.

DO NOT operate the generator in any enclosed or narrow

space. The gasoline engine that provides power to the

generator gives off DEADLY monoxide gas.

■

Always make sure the welder/ generator is secure on level

ground so that it cannot slide or shift around, endangering

workers. Also keep the immediate area free of bystanders.

■

High Temperatures – Allow the machine and engine to cool

before adding fuel or performing service and maintenance

functions. Contact with

hot

components can cause serious

burns.

CAUTION:

Emergencies

Always know the location of the nearest

firefire

fire

extinguisherextinguisher

extinguisher

and

first aid kitfirst aid kit

first aid kit

. Know the

location of the nearest telephone. Also know

the phone numbers of the nearest

ambulanceambulance

ambulance

,

doctordoctor

doctor

and

fire departmentfire department

fire department

.

Maintenance Safety

■

NEVER lubricate components or attempt service on a running

machine.

■

Always allow the machine a proper amount of time to cool

before servicing.

■

Keep the machinery in proper running condition.

■

Fix damage to the machine immediately and always replace

broken parts.

■

Dispose of hazardous waste properly. Examples of

potentially hazardous waste are used motor oil, coolant, fuel

and fuel filters.

■

DO NOT use plastic containers to dispose of hazardous

waste.

■

DO NOT pour waste, oil, coolant, or fuel directly onto the

ground, down a drain or into any water source.

RULES FOR SAFE OPERATION

PAGE 8 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)

OPERATION AND SAFETY DECALS

SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — PAGE 9

OPERATION AND SAFETY DECALS

P/N DCL160

PAGE 10 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)

SGW-250SS — SPECIFICATIONS

The maximum output of the engine listed above is applicable to supplying electrical power for continuous service at ambient

conditions in accordance with SAE Test cord J607. The above ambient conditions are at standard sea level, with a barometric

reading of 29.92 inches and a temperature of 60 degrees fahrenheit.

Generally, the engine output power will decrease 3 1/2% for each 1000 feet of altitude above sea level, and 1% for each 10

°°

°

F

fahrenheit above the standard temperature of 60

°°

°

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SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — PAGE 11

SGW-250SS — GENERAL INFORMATION

SGW-250SS FAMILIARIZATION

Generator

The MQ Power Model SGW-250SS welder/generator can

provide 200 amps of welding current when in the CV/DC

mode and 250 amps of welding current when in the CC/DC

mode. When used as a generator it can provide a maximum

of 7,200 watts of power.

Control Panel

The

control panelcontrol panel

control panel

is provided with the following:

z

One GFCI 120 volt receptacle, 30 amp (single-phase)

z

One 120 volt receptacle, 30 amp (single-phase)

z

One 120/240 volt receptacle, 30 amp (single-phase)

z

Main Circuit Breaker 265V @25 Amps

z

Circuit Protector Breaker (GFCI) 120V @20 Amps

z

Idle Control Switch

z

Starter Switch

z

Starter Button

z

Hour Meter

z

Ground Terminal

Welder Protection System

In the event of an overload, this welder/generator is equipped

with an welder protection system . If an overload is detected

while operating the welder/generator, the welder protection

system will shut down the engine.

Oil Pressure Warning Alarm

In the event of low oil pressure (engine), this welder/generator

is equipped with an engine protection fail safe system . If

low oil pressure is detected while operating the welder/

generator, the engine protection system will shut down the

engine.

If this condition (low oil pressure) should occur, please refer

to the engine troubleshooting table in this manual.

Excitation System

The SGW-250SS welder/generator uses a brushless

exciter to create rated output electricity. This system will

use the mechanical energy generated by the 3600 RPM

engine to spin the rotor (or armature) inside the generator

(or alternator end).

The motion created by the rotor (which holds copper coils)

spins inside a housing of permanent magnets called the

"STATOR". A magnetic field is created by the stator and

produces an electrical current.

Engine

The SGW-250SS is powered by an air-cooled, 4-cycle

HONDA gasoline engine. This engine is designed to meet

every performance requirement for generator. Reference

Table 1, page 9 for engine specifications.

In keeping with MQ Power's policy of constantly improving

its products, the specifications quoted herein are subject to

change without prior notice.

Figures 2 and 3 (pages 14-15) show the basic controls and

indicators for the SGW-250SS welder/generator.

PAGE 12 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)

Figure 1. SGW-250SS Dimensions

SGW-250SS — DIMENSIONS

SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — PAGE 13

Explanation of Chart:

This section is intended to provide the user with trailer ser-

vice and maintenance information. The service and main-

tenance guidelines referenced in this section apply a wide

range of trailers. Remember periodic inspection of the trailer

will ensure safe towing of the equipment and will prevent

damage to the equipment and personal injury.

It is the purpose of this section to cover the major mainte-

nance components of the trailer. The following trailer com-

ponents will be discussed in this section:



Brakes



Tires



Lug Nut Torquing



Suspension



Electrical



Brake Troubleshooting Tables

Use the following definitions with reading Table 2.

1. Fuel Cell - Provides an adequate amount of fuel for

the equipment in use. Fuel cells must be empty when

transporting equipment.

2. Braking System - System employed in stopping the

trailer. Typical braking systems are electric, surge, hy-

draulic, hydraulic-surge and air.

3. GVWR- Gross Vehicle Weight Rating (GVWR), is the

maximum number of pounds the trailer can carry, in-

cluding the fuel cell (empty).

SGW-250SS — TRAILER-SAFETY GUIDELINES

4. Frame Length - This measurement is from the ball

hitch to the rear bumper (reflector).

5. Frame Width - This measurement is from fender to

fender.

6. Jack Stand - Trailer support device with maximum

pound requirement from the tongue of the trailer.

7. Coupler - Type of hitch used on the trailer for towing.

8. Tire Size - Indicates the diameter of the tire in inches

(10,12,14, etc.), and the width in millimeters

(175,185,205, etc.). The tire diameter must match the

diameter of the tire rim.

9. Tire Ply - The tire ply (layers) number is rated in letters;

2-ply,4-ply,6-ply, etc.

10. Wheel Hub - The wheel hub is connected to the trailer’s

axle.

11. Tire Rim - Tires mounted on a tire rim. The tire rim must

match the size of the tire.

12. Lug Nuts - Used to secure the wheel to the wheel hub.

Always use a torque wrench to tighten down the lug

nuts. See Table 4 and Figure 5 or lug nut tightening and

sequence.

13. Axle - Indicates the maximum weight the axle can sup-

port in pounds, and the diameter of the axle expressed

in inches (see Table 3). Please not that some trailers

have a double axle. This will be shown as 2-6000 lbs.,

meaning two axles with a total weight capacity of 6000

pounds.

14. Suspension - Protects the trailer chassis from shocks

transmitted through the wheels. Types of suspension

used are leaf, Q-flex, and air ride.

15. Electrical - Electrical connectors (looms) are provided

with the trailer so the brake lights and turn signals can

be connected to the towing vehicle.

16. Application - Indicates which units can be employed

on a particular trailer.

CAUTION:

ALWAYS make sure the trailer is in good

operating condition. Check the tires for

proper inflation and wear. Also check the

wheel lug nuts for proper tightness.

PAGE 14 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)

SGW-250SS — TRAILER-SPECIFICATIONS

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SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — PAGE 15

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SGW-250SS — TRAILER-SPECIFICATIONS

PAGE 16 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)

Tires/Wheels/Lug Nuts

Tires and wheels are a very important and critical

components of the trailer. When specifying or replacing the

trailer wheels it is important the wheels, tires, and axle are

properly matched.

CAUTION:

DO NOT attempt to repair or modify a

wheel. DO NOT install in inner tube to

correct a leak through the rim. If the rim

is cracked,

the air

pressure in

the inner tube may cause pieces

of the rim to explode (break off)

with great force and cause serious

eye or bodily injury.

Tire Wear/Inflation

Tire inflation pressure is the most important factor in tire life.

Pressure should be checked cold before operation DO NOT

bleed air from tires when they are hot. Check inflation

pressure weekly during use to insure the maximum tire life

and tread wear.

Table 3 (Tire Wear Troubleshooting) will help pinpoint the

causes and solutions of tire wear problems.

CAUTION:

NOTE

ALWAYS wear safety glasses when removing

or installing force fitted parts. Failure to

comply may result in serious injury.

Suspension

The leaf suspension springs and associated components

(Figure 2) should be visually inspected every 6,000 miles for

signs of excessive wear, elongation of bolt holes, and

loosening of fasteners. Replace all damaged parts

(suspension) immediately. Torqued suspension components

as detailed in Table 4.

SGW-250SS —TRAILER SAFETY GUIDELINES

Figure 2. Major Suspension Components

SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — PAGE 17

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Lug Nut Torque Requirements

It is extremely important to apply and maintain proper wheel

mounting torque on the trailer. Be sure to use only the

fasteners matched to the cone angle of the wheel. Proper

procedure for attachment of the wheels is as follows:

1. Start all wheel lug nuts by hand.

2. Torque all lug nuts in sequence. See Figure 3. DO NOT

torque the wheel lug nuts all the way down. Tighten

each lug nut in 3 separate passes as defined by Table 5.

3. After first road use, retorque all lug nuts in sequence.

Check all wheel lug nuts periodically.

NOTE

NEVER use an pneumatic air gun to

tighten wheel lug nuts.

SGW-250SS —TRAILER SAFETY GUIDELINES

Figure 3. Wheel Lug Nuts Tightening Sequence

PAGE 18 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)

SGW-250SS —TRAILER-WIRING DIAGRAM

SGW-250SS DC WELDER/AC GENERATOR — PARTS & OPERATION MANUAL — REV. #2 (08/08/01) — PAGE 19

SGW-250SS —TOWING

To reduce the possibility of an accident while transporting

the generator on public roads, always make sure the trailer

(Figure 4) and the towing vehicle are in good operating

condition and both units are mechanically sound.

The following list of suggestions should be used when towing

your generator:

CAUTION :

Towing Safety Precautions

■

ALWAYS attach trailer's safety chain to bumper of towing

vehicle.

■

ALWAYS make sure the vehicle and trailer directional,

backup, brake, and trailer lights are connected and are

working properly.

■

The maximum speed (unless otherwise posted) for highway

towing is 45 MPH. Recommended off-road towing is not to

exceed 10 MPH or less, depending on type of terrain.

■

Place

chocked blocks

underneath wheel to prevent

rolling rolling

rolling,

while parked.

■

Place

support blocks

underneath the trailer's bumper to

prevent

tippingtipping

tipping

, while parked.

■

Use the trailer's hand winch to adjust the height of the trailer,

then insert locking pin to lock wheel stand in place, while

parked.

■

Avoid sudden stops and starts. This can cause skidding, or

jackknifing. Smooth, gradual starts and stops will improve

gas milage.

■

Avoid sharp turns to prevent rolling.

■

Remove wheel stand when transporting.

■

DO NOT transport generator with fuel in tank.

Check with your county or state safety

towing regulations department before

towing your generator. Vehicle towing

codes and regulations can vary from state

to state.

■

Make sure the hitch and coupling of the towing vehicle are

rated equal to, or greater than the trailer "gross vehicle weight

rating" (GVWR).

■

ALWAYS inspect the hitch and coupling for wear. NEVER

tow a trailer with defective hitches, couplings, chains etc.

■

Check the tire air pressure on both the towing vehicle and

the trailer. Also check the tire tread wear on both vehicles.

■

ALWAYS make sure the trailer is equipped with a "Safety

Chain".

Figure 4. Welder/AC Generator and Towing Trailer

PAGE 20 — SGW-250SS DC WELDER/AC GENERATOR— PARTS & OPERATION MANUAL — REV. #2 (08/08/01)

Figures 5 and 6 show the location of the controls and indicators.

The functions of each control or indicator is described below

and on the preceding page.

1. Welding Type (Wire/Stick) Selector Switch (CV/CC) –

Turn this selector switch to either the CV or CC for

welding. DO NOT turn this switch under load.

2. Current Range Selector Switch (CV/CC) – Turn this

selector switch to either the CV or CC for welding. DO

NOT turn this switch under load.

3. Current Control (CC) Adjustment Knob – Use this

control to adjust welding current. Low scale (50~120 amps),

High scale (90~250 amps). This function will not work in

the CV mode.

4. Voltage Control (CV) Adjustment Knob – Use this

control to adjust the welding voltage. This function will not

work in the CC mode.

5. Idle Control Switch – Regulates the engine speed when

the generator is under load.

6. Hour Meter – Indicates number of hours the welder has

been in use or engine has been running.

7. Oil Filler Port – Use this port when adding oil to the

engine.

8. Engine Air Cleaner – Prevents dirt and other debris

from entering the fuel system. Lift locking latch on air

filter cannister to gain access to filter element.

9. Main Circuit Breaker – This 2-pole circuit breaker provides

circuit protection (265V @30 amps) for the electric parts.

10. ON/OFF Switch – This switch is used to start and stop the

engine. Must be in th ON position (up) when starting the

engine. Place in the OFF position (down) to stop the engine.

11. Start Button – Press and hold this push-button switch

until the engine has started. The ON/OFF switch must be

in the ‘ON’ position in order for the start push-button switch

to start the engine.

12. Oil Filter – Provides oil filtering for the engine.

13. Fuel Cap – Remove this cap to add fuel. Add only clean

unleaded fuel. Always keep an adequate amount of fuel

in the tank. DO NOT top off. Wipe up any spilled fuel

immediately.

14. Battery Terminals – Connect these terminals to the

battery. Always pay close attention to the polarity of the

terminals when connecting to the battery, RED (positive),

and BLACK (negative).

15. Battery – Provides +12 VDC power for the generator.

When replacing battery (12V 35 AH) use only

recommended type battery.

Figure 5. SGW250SS Components 1

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Power Source Professionals.

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1

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5

6

11

9

10

15

12

7 8

13

14

SGW-250SS — CONTROLS AND INDICATORS

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